Solving Rail Related Problems


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This presentation gives an overview of rail related problems ESTEQ can help to solve. It is a combination of work from MSC Software, VI-Grade and ESTEQ

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Solving Rail Related Problems

  1. 1. Solving Your Rail Related Problems
  2. 2. Solving Your Rail Related ProblemsRail vehicle simulations Dynamics, stability, derailment… Detailed Rail-Wheel interaction, wear… Control systems, brake systems, traction… Wagon interaction, buffer impact…Permanent way simulations Rail stresses, deformation… Substructure stresses, deformation…Component simulations Stress, Fatigue…
  3. 3. The Solution Triangle
  4. 4. The Technology
  5. 5. Virtual Prototyping DefinedFunctional simulation of real-world systems Reduces time-intensive, costly, hardware build- test-refine cycles Improves quality (cut warranty and repair/maintenance costs)
  6. 6. Virtual Prototyping DefinedFunctional simulation of real-world systems Reduces time-intensive, costly, hardware build- test-refine cycles Improves quality (cut warranty and repair/maintenance costs)
  7. 7. Virtual Prototyping Defined Thermal Comfort and Air Quality in CarriagesFunctional simulation of real-world systems Reduces time-intensive, costly, hardware build- test-refine cycles Improves quality (cut warranty and repair/maintenance costs)
  8. 8. VI-RailApplications
  9. 9. The Functional Digital Train Full Railway System Bogie Body Accessories Permanent Way Suspensions Interference Buffers Track beams Wheels / Contact Packaging Brakes Ballasts Dampers Passenger Safety Engine groups Bridges Active devices Pantographs
  10. 10. The Functional Digital Train Full Railway System Bogie Body Accessories Permanent Way Suspensions Interference Buffers Track beams Wheels / Contact Packaging Brakes Ballasts Dampers Passenger Safety Engine groups Bridges Active devices Pantographs
  11. 11. Integration Platform CAD FEA Integration Platform Durability Controls Vibration In-House Solutions
  12. 12. VI-RailVehicle Stability• Automatic Stability Analysis • Specification of critical damping to determine stability (0%, 5%,...) • Specification of conicity range for automatic generation of stability map
  13. 13. VI-RailTraction/Braking• Friction coefficient variability • With track distance • With creepage • With lateral coordinate on rail / wheel Friction Coefficient
  14. 14. VI-RailTraction/Braking• Application: detailed drive simulation during traction maneuver • Oscillations in drive system can be carefully tracked down and eliminated
  15. 15. Packaging/Interference • DMU/Replay integrates ADAMS/PPT into CATIA v5 to perform virtual collision check and envelopes calculation • Conceptual collision detection also available in the ADAMS environment
  16. 16. Integrated Flexibility/DurabilityFlex body representationStress recovery calculationand color map visualizedinto ADAMS/PPT
  17. 17. Integrated Vibration AnalysisFrequency response optimization of rideindexes according to Equivalent conicity Suspension stiffnesses Damper characteristicsImmediate information about qualitativeinfluence of design changes on runningcomfort
  18. 18. Integrated DOE/OptimizationThrough the use of ADAMS/Insight: The scaling factors for all VI/Rail components are automatically defined Several design changes can be automatically investigated Results are formatted in 3D response surfaces, animations, and HTML pages which can be directly published for the whole engineering team Lat Acc RMS 0,65 0,6 0,6-0,65 0,55 0,55-0,6 0,5-0,55 0,5 0,45-0,5 0,45 0,4-0,45 1,4 0,4 1 0,6 PS ZStiff 0,8 1 0,6 Factor PD Damping Factor 1,2 1,4
  19. 19. VI-Rail Detailed Wheel/Rail ContactReal Lift-Off Representation
  20. 20. VI-Rail Detailed Wheel/Rail ContactFlanging with Multi-Point-Contact
  21. 21. VI-Rail Detailed Wheel/Rail ContactAllows to switch between different profiles along the trackImplemented for WRGEN contact element
  22. 22. VI-Rail Detailed Wheel/Rail ContactPossibility to change wheel radius along circumferenceAvailable when using WRGEN contact elementDifferent radii specified in wheel configuration matrix
  23. 23. From Concept to Prototype• Functional Virtual Prototyping as a complete solution for railway engineering • Confirmed by several customers and several applications • Enabling communication between the engineering tools • Rely on railway expertise and powerful, specialistic tools through strategic relationships
  24. 24. REFERENCES
  25. 25. Deutsche Bahn AGBusiness: European railway operatorChallenge: Evaluate stresses developing in rail bridges from high speed trainsSolution: Using ADAMS/Rail in combination with FE to virtually estimate the bridge mid-span stress time historiesValue: Enables prediction of stress histories without expensive physical testing“A high flexibility in modeling different types of vehicles hasbeen reached by taking advantage of the template-builderstructure… to build up different ICE assemblies by referencingsimply to an ICE bogie and an ICE car body template.” --Manfred Zacher, Deutsche Bahn AG
  26. 26. RDSOBusiness: Research arm of the Indian Ministry of RailwaysChallenge: Develop a flat rail car for safe operation at 100 km/hSolution: Using ADAMS/Rail and NASTRAN with field wheel/rail measurements to virtually evaluate acceptance criteriaValue: Virtual tests demonstrated that design shall pass the field criteria of Indian Railways“ADAMS/Rail is for RDSO a necessary virtual prototyping tool toensure good financial health of the organization and reduction incost of development and testing of a new design.” -- Nitin Chowdary Director, Vehicle Dynamics Group
  27. 27. TrenitaliaBusiness: European railway operatorChallenge: Implement braking device in experimental railway vehicleSolution: Behavior of the WSPD (Wheel Slide Protection Device) active system is investigated using ADAMS-Matlab Co- SimulationValue: Able to optimize slide protection device with the help of virtual prototyping“The proposed model has a behaviour qualitatively andquantitatively analogous to the on line tests.” -- P. Presciani Manager, UTMR Trenitalia
  28. 28. BombardierBusiness: Railway rolling stock manufacturerChallenge: Rapidly develop an optimized traction control systemSolution: Using MSC.Patran/Nastran, ADAMS/Rail with ADAMS/Controls + MATLAB as integrated virtual prototyping solution for mechatronicsValue: Increased confidence in product“Commissioning of traction control could be finished in a shorttime with very good results to the satisfaction of our customer,even though the conditions were very difficult.” -- Peter Haese Traction Systems Engineering
  29. 29. Alstom Business: European railway vehicles manufacturer Challenge: Investigate poor performance caused by car body torsion interaction with bogie hunting Solution: Integrated VI/Rail bogie model with FE carbody Value: Overall comfort performance optimize, resulting in wide commercial success“A complete DOE analysis enabled the engineers to test thedynamic behaviour of the complete system and to find out theoptimal parameter settings which restricts the vibration of theconstruction and therefore optimises the comfort behaviour.” -- Pascal Geoffroy Manager, Rolling Stock
  30. 30. AlstomBusiness: Railway vehicles manufacturerChallenge: Optimize new streetcar for rollover stability and derailment avoidanceSolution: Evaluated the vehicle behavior virtually to optimize the designValue: Improved safety; greater confidence“The simulation produced results in agreement with allservice conditions and the overall dynamic behavior.Derailment and rollover stability measurements havebeen matched with a maximum error of 3%.” -- Massimo Lenti Manager R&D, Alstom IPS
  31. 31. Case Study:GE TransportationBusiness:North American locomotive manufacturerChallenge:Investigate the effect of wheel back-to-backdistance on locomotive stability and safetySolution:Parametric model built in ADAMS/Rail andrun through standard suite of maneuversValue:Met customer critical-to-qualityrequirements on locomotive design “We have done a lot of wonderful work using ADAMS.” -- Jingjun Zhang Control and Auxiliary Systems
  32. 32. Patentes TalgoBusiness: Railway rolling stock manufacturerChallenge: Meet UIC518 acceptance requirements when operating on tracks with different gaugesSolution: Virtual comfort and safety studies for different system configurationsValue: Fulfilled UIC518 requirements “The results achieved have been coherent regarding tilting in curves, accelerations on car bodies, contact forces, and guidance system.” -- Emilio Garcia, Manager, Talgo
  33. 33. Patentes TalgoBusiness: Railway rolling stock manufacturerChallenge: Investigate dynamic behavior of high- speed trainSolution: VPD and MSC.ADAMS/RailValue: Simulation enables to virtually perform design certification with less cost and to investigate system behavior through tests which cannot be performed physically“Simulation reduces the cost of design. It is afundamental tool to present technical informationto our customers and ensure the viability of ourproducts. It facilitates the investigation of designissues like comfort and derailment safety.” -- Emilio Garcia, Manager, Talgo
  34. 34. Skoda LocBusiness: Railway vehicle manufacturerChallenge: Establish locomotive bogie design between different variantsSolution: ADAMS/Rail detailed models of locomotives with different traction devicesValue: Recommend for implementation better arrangement for running gear thanks to simulation results “Thanks to simulation it has been possible to choose the most cost-effective design for the locomotive bogies, by evaluating the behavior of all different variants.” --Vaclav Kraus Skoda Locomotive
  35. 35. VUKVBusiness: Railway vehicle manufacturerChallenge: Position itself successfully in a global marketSolution: Following an extensive benchmarking, implemented the state-of-the-art simulation technology from MSC.SoftwareValue: Show competence presenting highly sophisticated solutions to their customers “By using MSC.Software products we have been able to acquire new customers and, most significantly, open new markets. Our initial estimate of a three-year payback period proves to be significantly shorter.” -- Zdenek Malkovsky VUKV
  36. 36. Case Study: Association of American Railroads Challenge: Perform crash tests on railcar prototype Solution: VPD from MSC.Software (based on LS Dyna) Value:After correlation with physical testing, VPD can be used to perform virtual crash tests with enormous cash saving
  37. 37. Voith TurboBusiness: Supplier for locomotive drive systemsChallenge: Optimize the complete locomotive + drive assemblySolution: Nastran and ADAMS Functional Digital Train with FE components enabled them to improve traction/braking and impact performanceValue: Improved collaboration with customer. Better information earlier in the process
  38. 38. Fiat CRFBusiness: European service providerChallenge: Develop a semi-active lateral suspension for a new tilting trainSolution: Integrating train model in ADAMS/Rail with MATLAB model of sky-hook suspension designValue: Increased low-frequency ride comfort“Tilting system modifications investigated with theintegrated virtual prototype enabled us to reachreduction of nearly 50% of the lateral ride figures.” -- Mauro Montiglio Manager, Vehicle Engineering Projects
  39. 39. Fiat CRFBusiness: European service providerChallenge: Develop innovative railway wheelsets with outstanding reliability performancesSolution: ADAMS/Rail model of railcar including MSC.Nastran flexible wheelsetsValue: Predict load spectra with simulation: increase confidence in design Average service (400 km)“Significant developments in the design of railwaywheelsets in terms of improved durability, reduced noiseand vibration impact, and lower life cycle costs are straight Vertical forceexpected to be the final result of the project.” curve total -- K. Bel Knani Manager, HIPERWHEEL Project, Fiat CRF 0 1 2 3 4 5 10 10 10 10 10 10
  40. 40. Case Study:Warsaw UniversityChallenge:Buffer impact simulationSolution:VPD from MSC.Software (based on ADAMS/Raildetailed buffer model mounted on completevehicles)Value:Guarantee safe performance of buffer
  41. 41. Nedtrain ConsultingBusiness: Railway Services ConsultantChallenge: Improve railcar efficiency by reducing delays due to technical failureSolution: Full virtual prototype of door system (including electric and pneumatic)Value: Virtually improve operational safety of door opening system“The simulation results will be used to introduceimprovements in the door system operation.” -- E.J.J. De Jong Nedtrain Consulting
  42. 42. Nedtrain ConsultingBusiness: Railway Services ConsultantChallenge: Develop a compact system to measure train weight and wheel defects (GOTCHA)Solution: Measuring site ADAMS model to gain insight in the dynamic behaviour of the measuring systemValue: GOTCHA already used to monitor wheel tread quality on almost all electrical NS rolling stock“Using the model the processing of themeasuring signal was optimised resulting in ahigh accuracy and reproducibility of the system.” -- E.J.J. De Jong Nedtrain Consulting
  43. 43. RTUBusiness: Railway industry consultantChallenge: Simulate UK freight wagon ride acceptance testsSolution: ADAMS/Rail model of freight wagon with custom simulation/postprocessing eventValue: Allow prediction of the results of the UK vehicle acceptance test within simulation environment “With ADAMS/Rail the effects of modifications to the vehicle can be evaluated before the actual test procedure is carried out.” --Yann Bezin Rail Technology Unit, MMU
  44. 44. Corus - RTUBusiness: Railway industry consultantChallenge: Develop a methodology to virtually investigate rolling contact fatigueSolution: ADAMS/Rail vehicle models in combination with non linear FE rail-ballast modelsValue: Virtually predict the typical stress response of rail when subjected to vehicle loads“The forces predicted from the vehicle dynamicmodelling using Adams/Rail are in broad agreement withmeasured data from on site instrumentation. Thepredicted forces can then be used with confidence inboth the global track and contact stress models.” --Stephen Blair Corus Rail Technologies
  45. 45. Transnet Freight RailBusiness: largest Railway company in South AfricaChallenge: predict by simulation the loads in the overhead system, and the pantograph during operation, in order to optimise the tension in the overhead system to minimise the forces.Solution: MSC.Marc for a unique capability of line/line contact approachValue: The cost of the physical damage is around € 250k, but the cost of the lost revenue on the unsused lines runs into millions.
  46. 46. How Can We Help You?
  47. 47. With The Right Tools…
  48. 48. With The Right Tools…Product Lifecyle Management (PLM)Computer Aided Drawing (CAD)Finite Element Analysis (FEA)Systems & Controls (S&C)Multi Body Dynamics (MBD)Computation Fluid Dynamics (CFD)Test & Measurement (T&M)
  49. 49. Linking to the Rail CommunityWhich Tools does the Rail Community use? MSC Masterkey Access to Multiple specialised CAE tools Flexible licensing system All products integrate easily VI-Rail Rail focused MBD tool Runs on top of MSC Adams Integrates fully with MSC Masterkey products
  50. 50. Supporting the Rail CommunityConsulting Services VI-Rail Simulations Thermal Simulations Thermal Structural Analysis (UIC510-5)
  51. 51. With The Right People…
  52. 52. With The Right People… Product Training Discipline Training THRIP Program @ UP Chair in Railway Engineering University Program Recruitment
  53. 53. With The Right Ways…
  54. 54. With The Right Ways… Product Support Service Level Agreement (SLA) On-Site training On-Site Mentoring Knowledge Transfer Internship program
  55. 55. ESTEQ is your solution!
  56. 56. Who is ESTEQ? • Engineering Solutions focused company • Since 1994 • Head office in Gauteng, offices in Western Cape & KwaZulu Natal • 45 Employees • 22 Mechanical Engineers • 3 Industrial Engineers • 1 Electrical Engineer • 1 Civil Engineer ? • Brings World Class Technology to SA: • SIEMENS, MSC Software, HBM, Mentor Graphics, Endevco… • Who do we help? • Over 1500 local companies • 16 local Universities • Over 5 000 users
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